US008209927B2

(12) United States Patent (10) Patent No.: US 8,209,927 B2 Cottier et al. (45) Date of Patent: Jul. 3, 2012

(54) STRUCTURAL FIBER CEMENT BUILDING 37.2%J. w A 8. 3. itygeberg et al.1 MATERLALS 2,377,484 A 6, 1945 Elmendof 2,676,892 A 4, 1954 McLaughlin (75) Inventors: John Sydney Cottier, Oatley (AU); 2,797,201 A 6, 1957 Veatch December Rose Cowen, Yucaipa, CA 2.978,340 A 4, 1961 Veatch et al. (US); Remi Dunoyer, Randwick (AU); 39. A 233 Malik Steven Duselis, Baulkham Hills (AU); 3.264,135 A 8, 1966 Sin James Albert Gleeson, North Curl Curl 3.35 14 14 A 5, 1967 Veli (AU); Amitabha Kumar, Claremont, 3,360,392 A 12/1967 Modet al. CA (US) 3,365,315. A 1/1968 Becket al. 3,501,324 A 3, 1970 Kubo ck (73) Assignee: James Hardie Technology Limited, SE A 3229 East ...... 52,125.5 Dublin (IE) 3,748,100 A 7, 1973 ForSeth (*) Notice: Subject to any disclaimer, the term of this (Continued) patent is extended or adjusted under 35 FOREIGN PATENT DOCUMENTS U.S.C. 154(b) by 928 days. AR 2O6788 A1 8/1976 (21) Appl. No.: 11/961,749 (Continued) (22) Filed: Dec. 20, 2007 OTHER PUBLICATIONS O O Skaggs, C.B. et al "Applications of Rheological Modifiers and (65) Prior Publication Data Superplasticizers in Cementitious System” American Concrete Insti US 2009/0162602 A1 Jun. 25, 2009 tute SP (1994), SP-148, 189-207. (Continued) (51) Int. Cl. E04C I/00 (2006.01) Primary Examiner — Basil Katcheves (52) U.S. Cl...... 52/309.3: 52/125.5 (74) Attorney, Agent, or Firm — Knobbe, Martens, Olson & (58) Field of Classification Search ...... 52/309.3, Bear, LLP 52/125.5; 428/192 See application file for complete search history. (57) ABSTRACT (56) References Cited A structural fiber cement sheet containing cementitious matrix and reinforcing cellulose fibers distributed throughout U.S. PATENT DOCUMENTS the matrix having a dry density less than 1.25 g/cm, a thick ness less than 0.7500 in, and able to withstand uniform loads 815,801 A 3, 1906 Depew etal. of 200 psfor greater according to test method of Section 1,571,048 A 1, 1926 Garrow 1914, 163 A 6, 1933 Randall 6.4.2.4 of PS2 and with a deflection of less than 0.067 inches 2,156,308 A 5, 1939 Schuh at 60 psfwhen spaced on a span of 24 inches or less on center. 2,156,311 A 5, 1939 Schuh 2,175,568 A 10, 1939 Haustein 7 Claims, 7 Drawing Sheets

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U.S. Patent Jul. 3, 2012 Sheet 2 of 7 US 8,209,927 B2

U.S. Patent Jul. 3, 2012 Sheet 3 of 7 US 8,209,927 B2

U.S. Patent Jul. 3, 2012 Sheet 4 of 7 US 8,209,927 B2

U.S. Patent Jul. 3, 2012 Sheet 5 Of 7 US 8,209,927 B2

U.S. Patent Jul. 3, 2012 Sheet 6 of 7 US 8,209,927 B2

U.S. Patent Jul. 3, 2012 Sheet 7 Of 7 US 8,209,927 B2

US 8,209,927 B2 1. 2 STRUCTURAL FIBER CEMENT BUILDING additive is in the range of from about 7 to about 12 weight MATERALS percent. The single floor sheet has a dry density less than 1.25 g/cm, a thickness less than 0.7500 inches, and able to with stand uniform loads of 200 psfor greater according to test BACKGROUND OF THE INVENTION method of Section 6.4.2.4 of PS2 and with a deflection of less than 0.067 inches at 60psfwhen spaced on a span of 24 inches In residential construction, flooring for wet areas (bath on center or less. rooms, kitchens, laundry rooms, etc.) typically involves first In accordance with another embodiment of the present creating a “sub-floor, which is attached directly to the under invention, a flooring system is provided which includes elon lying Support frame (studs and/or joists). The Sub-floor typi gate horizontally-spaced Supporting members each having an cally consists of wood-based products such as particle board, 10 upper Surface Substantially coplanar, a waterproof single press board, plywood, oriented strand board (OSB), or other flooring grade fiber cement sheet disposed on top of and in Such timber-based products. direct contact with the upper Surface of the Supporting mem In areas where tile is desired, it is common practice to bers, a layer of adhesive Substantially covering the single attach underlayment (also known as backerboard) to the Sub flooring grade fiber cement sheet, and a floor covering floor and then affix tile on top of the underlayment. Having to adhered to the single flooring grade fiber cement sheet by the haul, size, and install two materials prior to installing tile is 15 adhesive. time-consuming and increases labor costs. Also, given that The flooring system may include multiple single flooring the wood Sub-floor is highly Susceptible to water damage and grade fiber cement sheet interlockingly engaged with one another by connectors. In certain embodiments, the connec lacks dimensional stability, fiber-reinforced cement (FRC) tors are tongue and groovejoint respectively defined on oppo products such as water-resistant building sheets have been site longitudinal edges of the single flooring grade fiber used as underlayments and are known in the art. Fiber-rein cement sheets. forced cement underlayments provide a moisture resistant In accordance with yet another embodiment of the present barrier between the sub-floor and tile. However, if this water invention, a building sheet is provided which includes a top proofing barrier is not installed correctly, water may penetrate face, a bottom face, and two sets of opposing parallel edges. through to the underlying Sub-floor. The dimensional insta At least one edge contains agroove formed and the groove has bility of the wood sub-floor could then disrupt the adhesion of 25 a membrane situated inside encapsulating an adhesive. The the tiles to the underlayment or worse, the integrity of the membrane is configured to resist puncture during transport underlying structure. and prior to installation and configured to permit puncture upon Sufficient contact with an edge of an adjacent building SUMMARY OF THE INVENTION sheet during installation. 30 In accordance with yet another embodiment of the present In one embodiment, there is provided a single floor grade invention, a wall system is provided which includes elongate composite fiber cement building material suitable for use in a vertically-spaced supporting members each having a surface variety of building applications, including wet area flooring. Substantially coplanar, and a waterproof fiber cement sheath ing layer in contact with at least a portion of the Surface of the The single floor grade composite fiber cement building mate Supporting members, wherein the fiber cement sheathing rial may be secured directly to the floor joists, thus eliminat 35 layer has a dry density less than 1.25 g/cmandable to endure ing the need for installation of both a sub-floor and underlay racking shear testing and wind load test of the Acceptance ment separately. Composite fiber cement building materials Criteria (AC) 90 as set by the International Code Council disclosed herein are lightweight, yet strong. Evaluation Services (ICC-ES). In accordance with one embodiment of the present inven Those skilled in the art will further appreciate the advan tion, a fiber cement sheet is provided, which may be used as tages and Superior features of the invention mentioned above a waterproof single flooring grade fiber cement sheet in wet 40 together with other important aspects upon reading the area flooring applications. The fiber cement sheet includes a detailed description which follows in conjunction with the cementitious matrix and reinforcing cellulose fibers distrib drawings, wherein: uted throughout the matrix. The fiber cement sheet has a dry density less than 1.25 g/cm, a thickness less than 0.7500 BRIEF DESCRIPTION OF THE DRAWINGS inch, and able to withstand uniform loads of at least 200 psfor 45 greater according to test method of Section 6.4.2.4 of PS2 FIG. 1 is a perspective view of a prior art flooring system. published by the US Department of Commerce and with an FIG. 2 is a perspective view of one embodiment of a floor average deflection of less than 0.067 inches at 60 psf. able to ing system in accordance with the invention; withstand impact loads of 75 ft/lbs and a proof load of 400 FIG. 3 is a perspective view of one embodiment of a wall pounds or greater following impact according to ASTM E 661 50 system in accordance with the invention; Procedure A with a deflection of less than 0.108 inches under FIG. 4 is a perspective view illustrating a flooring system a 200 pound load after impact, and able to withstand concen with a fiber cement sheet containing tongue and grove joint trated Static loads of 550 pounds or greater according to connectors in accordance with the invention; ASTM E 661 with a deflection of less than 0.108 inches under FIG. 5 is a cross-section view illustrating a flooring system a 200 pound load when spaced on a span of 24 inches or less 55 with fiber cement sheets containing tongue and grove joint oncenter. The fiber cement sheet is able to withstand uniform connectors in accordance with the invention; loads of at least 300 psfor greater with a deflection of less than FIG. 6 is a cross-section view illustrating a flooring system 0.067 inches at 100 psfwhen spaced on a span of 24 inches on with a plurality of fiber cement sheets interconnected using a center or less when tested according to the test method of tongue and groove joint to form a panel; and Section 6.4.2.4 of PS2. FIG. 7 is a cross-section view illustrating a flooring system In accordance with another embodiment of the present 60 with fiber cement sheets containing an adhesive membrane in invention, a single floor sheet is provided which may include the grove joint connector in accordance with the invention. a hydraulic binder, aggregate, fibers, at least one low density additive, and additives. The hydraulic binder is in a range of DETAILED DESCRIPTION OF PREFERRED about 25 to about 40 weight percent. The aggregate is in a EMBODIMENTS range of about 30 to about 45 weight percent. The fibers are in 65 the range of from about 10 to about 12 weight percent, pref In the description that follows like parts are marked erably about 11 weight percent. At least one low density throughout the specification and drawings with the same ref US 8,209,927 B2 3 4 erence numerals, respectively. The drawings figures may not are concentrated Static loads, impact loads, and uniform loads necessarily be to scale and certain elements may be shown in as well as the deflections with different loads. generalized or somewhat schematic form in the interest of Strength, however, is not the only consideration for a Suit clarity and conciseness. able flooring product. Not only should the flooring be strong, Referring to FIG. 1, there is illustrated a prior art flooring but have a high handleability. There is difficulty in making a system generally designated by the numeral 100. Flooring flooring sheet that has a low density, is nailable, and has a system 100 is constructed of multiple flooring layers and is thickness comparable to wood flooring sheets and overcomes assembled by first constructing Supporting members or floor the disadvantages of the wood flooring sheets. While fiber joists 1, which generally consist of elongated beams spaced sheet composite products may be formulated (by adding apart at equal distances and parallel to one another. Support 10 material) to meet minimum strength requirements, the result ing members or floor joists 1 may be constructed of wood, ing sheets could easily be either too dense or too thick to be a steel or other suitable material. Attached to the top side of the viable product. When the flooring has too high a density, Supporting members or floor joists 1 is a wood-based Sub fastening of the flooring to the Supporting members becomes floor 3. The sub-floor 3 is generally flat and fastened to the difficult and pre-drilled holes are often be necessary to fasten upper-side of supporting members/floor joists 1 with Suitable 15 the flooring to the Supporting members easily. This would fasteners. Sub-floor 3 is formed of wood, such as plywood or lead to increased cost to manufacture and reduce of ease of oriented strand board (OSB). An underlayment 5 is then use. Also, if the density of the flooring sheet is high, the attached to the upper surface of the subfloor 3 by suitable weight of the sheet increases. If the sheet is too heavy, it fasteners, which may also include, additionally or alterna becomes difficult to carry, possibly requiring more than one tively, applying an adhesive. A layer of adhesive 7 is then person to handle and install the flooring. This is also a diffi spread on the top face of underlayment 5 and then tiles 9 are culty if the sheet is too thick. The sheet may become awkward laid on top of underlayment 5 to complete the floor construc and difficult to handle. There may be the possibility of requir tion. ing more than one person to handle and install the flooring. Referring to FIG. 2, there is illustrated a flooring system in Further, if the flooring material is used only in wet areas and accordance with the invention and generally designated by the material is thicker than conventional flooring materials, the numeral 200. The flooring system 200 is adapted for 25 the flooring will be uneven from room to room. flooring for use in “wet areas' such as for example, bath Referring further to FIG. 2, a layer of adhesive 25 may be rooms, kitchens, and laundry rooms. The flooring system 200 applied directly to the top surface of fiber cement sheet 23, is characterized by elongate horizontally-spaced supporting substantially covering the fiber cement sheet 23. Thereafter, members 21, each having an upper Surface Substantially co floor coverings such as tiles 27 are placed as desired on the planar with the other supporting members 21. As will be 30 fiber cement sheet 23, and are bonded to the fiber cement appreciated from reviewing FIG. 2, the Supporting members sheet 23 by adhesive 25. Suitable adhesives 25 include, but 21 run from wall to wall, wall to beam, or beam to beam, to are not limited to, concrete mortars, dry-set Portland cement Support the floor. The Supporting members 21 may be made of mortar, standard thin-set mortar, modified thin-set mortar, various Suitable materials including wood, Steel and concrete. latex modified thin-set mortar, fortified thin-set mortar, poly One common Supporting member 21 is a joist. In flooring mer modified thin-set mortar, epoxy mortar, organic mastic, construction, the joist is supported by an underlying beam in 35 or any other Suitable adhesive. Tiles may be ceramic, quarry, a repetitive fashion as is known in the art. The joists are pavers, cement, porcelain, brick, precast terraZZo, natural typically spanned apart at 16 inches, 19.2 inches, or 24 inches stone, glass, or other material as are suitable in the art. It may On Center. be appreciated that the final flooring may not be limited to tile, Referring further to FIG. 2, the supporting members 21 but may include, for example, carpet, Stone, masonry, vinyl, directly Support a single flooring grade cementitious sheet 23 40 wood, laminate, or any other suitable floor finishing material. in accordance with the present invention. Such flooring materials may be attached using adhesive, In certain embodiments, the single flooring grade cemen Staples, nails, tacks, etc. titious sheet 23 may be a fiber cement sheet (described further The preferred embodiments of the present invention below) in accordance with the present invention. describe a fiber-reinforced cement formulation comprising a In one preferred embodiment of the present disclosure, 45 cementitious matrix and various components distributed sheets are specifically configured for use as structural floor throughout the matrix. The fiber-reinforced cement formula ing. In the construction industry, structural flooring is consid tion of the present invention comprises a hydraulic binder, ered either sheathing grade or single floor grade. Sheathing aggregates, reinforcing cellulose fibers, low density modifi grade flooring, also referred to as Sub floor, requires an addi ers, and other additives. The formulation is optimized to tional layer of flooring material Such as underlayments, wood 50 provide a final fiber cement sheet product which has a dry strip flooring, concrete topping, membranes, or other Such density less than 1.25 g/cm when formed at a thickness less functional flooring material prior to finishing with tiles. than 0.7500 inch, able to withstand uniform peak loads at Single floor grade sheets do not require an additional func least 200 psf with an average deflectionless than 0.067 inch at tional layer. In one embodiment of the present disclosure, 60 psf. able to withstand impact loads of 75 ft/lbs and a proof fiber cement sheets are engineered and configured as single 55 load of 400 pounds or greater following impact according to floor grade. One advantage of the fiber cement single grade ASTM E 661 Procedure A with a deflection of less than 0.108 flooring sheets is that it does not require a tile underlayment to inches under a 200 pound load after impact, and able to adhere tiles to the flooring. The disclosed embodiments alle withstand concentrated static loads of 550 pounds or greater viate the necessity of hauling, sizing, and installing two layers according to ASTM E 661 with a deflection of less than 0.108 of flooring prior to installing tile. The fiber cement single inches under a 200 pound load when spaced on a span of 24 grade flooring sheet is also water resistant, dimensionally 60 inches or less on center. The fiber cement sheet can actually stable, and is not susceptible to water damage. withstand uniform peak loads of at least 300 psf with a deflec Structural floors are required to meet certain standards. tion less than 0.067 inch at 100 psf when spaced on a span of Fiber cement structural floors must be in compliance with the 24 inches or less on center. Acceptance Criteria For Fiber Cement Sheet Structural Floor One preferred formulation of one embodiment of the Sheathing AC367 as set by the International Code Council 65 present invention comprises a hydraulic binder, aggregate, Evaluation Services (ICC-ES). The structural floors must reinforcing cellulose fibers, low density modifiers, and addi meet the minimum requirements for structural loads, which tives. The hydraulic binder is preferably Portland cement but US 8,209,927 B2 5 6 can also be, and is not limited to, pulverized material in the The product produced is preferably pre-cured (for about 12 solid, dry state which, when mixed with water, yields plastic hours) to establish the formulation to set and then cured by mixtures that are able to set and harden. Examples of suitable air-cure (approximately 28 days) or more preferably, by auto hydraulic binders include but are not limited to, high alumina claving (about 12 hours). cement, ground granulated blast furnace slag cement, gyp In certain embodiments, a sealant or sealant combination is Sum, magnesium phosphate cement, geo-polymer, or any applied to the fiber cement sheet. The sealant or sealant com other suitable material. The quantity of hydraulic binder in bination may be a polymer emulsion or Solution and or a the formulation is preferably between about 10 to 60 wt % water repellent, such as, for example, silanes, siloxanes, based on the total dry ingredients, more preferably about 20 to waxes or stearates, to decrease the fiber cement sheets water 45 wt % based on the total dry ingredients, and most prefer 10 absorption in order to strengthen the sheet and promote its ably about 25 to 40 wt % based on the total dry ingredients. natural water resistant properties. The coating system may The aggregate is preferably ground silica sand but can also encompass air drying, multiple component systems, reactive be, and is not limited to, amorphous silica, silica fume, diato chemical curing, thermo curing or radiation curing coatings maceous earth, rice hull ash, blast furnace slag, granulated (e.g., electron beam, ultra violet, near infrared, micro wave) slag, steel slag, mineral oxides, mineral hydroxides, clays, 15 or combinations utilizing any curing or drying techniques for magnasite or dolomite, metal oxides and hydroxides, poly water based, solvent based or 100% solids (wet or powder) meric beads, or mixtures thereof. The quantity of the aggre coating systems. gate in the formulation is preferably between about 10 to 70 Turning to FIG. 3, there is illustrated a wall system in wt % based on the total dry ingredients, more preferably accordance with the invention and generally designated by about 20 to 50 wt % based on the total dry ingredients, and the numeral 300. The wall system 300 is characterized by most preferably about 30-45 wt % based on the total dry elongate vertically-spaced Supporting members 31, each hav ingredients. ing a surface Substantially co-planar with the other supporting The reinforcing cellulose fibers preferably are thermome members 31. As will be appreciated from reviewing FIG. 3, chanically or chemically-refined fibers, such as cellulose the Supporting members 31 (commonly referred to as framing fibers produced by the Kraft process, which may be bleached 25 or “studs') run from floor to ceiling, floor to beam or beam to or unbleached. Other forms of reinforcing fibers may also be beam. The supporting members 31 may be made of various used examples of which include, but are not limited to, Suitable materials including wood, steel, brick and concrete. ceramic fiber, glass fiber, mineral wool, Steel fiber, and Syn The Supporting members 31 are typically spanned apart at 16 thetic polymer fibers such as polyamides, polyester, polypro inches or 24 inches on center. pylene, polymethylpentene, polyacrylonitrile, polyacryla 30 In a preferred embodiment, the wall system comprises mide, Viscose, nylon, PVC, PVA, rayon, glass ceramic, elongated Supporting members having an outer Surface Sub carbon, or any mixtures thereof. Useful reinforcing cellulose stantially coplanar and a waterproof sheet on top of the outer fibers may also include chemically treated cellulose fibers, Surface of the Supporting members. The Supporting members such as fibers treated with hydrophobicity agents, biocides, run from floor to ceiling, flooring to beam or beam to beam. etc. When cellulose fibers are used, they are preferably 35 The Supporting members may be made of wood, steel, brick, refined to a degree of freeness of between 20 and 800 Cana or concrete. Wall Supporting members are commonly referred dian Standard Freeness (CSF), more preferably 200 to 500 to as framing. The framing consists of studs, which are ver CSF. The reinforcing cellulose fibers may be present in a tical framing member used to construct walls and partitions. concentration of 9.5 to 12 wt % based on the weight of the dry Referring further to FIG. 3, the supporting members 31 formulation. directly support one embodiment of a waterproof engineered The low density additives (LDA) preferably are micro 40 fiber cement sheet 33 formed in accordance with the present spheres, but may include a variety of Substances which assist invention as described above. The wall system 300 may be in achieving lower density in the fiber cement substrate. adapted for structural sheathing and may be designed to with Examples of suitable low density additives include, but are stand racking shear and wind loading. not limited to, microspheres, callsil, treated callsil, polymeric Referring to FIGS. 4-6, there is illustrated an engineered spheres, polymeric beads, polystyrene beads, expanded ver 45 fiber cement sheet according to one embodiment of the miculite, expanded perlite, expanded shale, expanded clay, or present invention generally designated by the numeral 400. any other suitable material. One preferred low density addi The fiber cement sheet 400 is characterized by a fiber cement tive is microspheres. The amount of low density additive in sheet having a top face 41, a bottom face 43, and cooperating the formulation is preferably between about 7 to 12 wt %. connections 45, 47 on longitudinally opposed edges. The It should also be noted that additional additives can be 50 connections serve to resist relative movement, and in particu optionally incorporated into the fiber cement formulation lar co-planar misalignment, between abutting sheets along including but not limited to, fillers, dispersing agents, silica the joints. It will be appreciated by those skilled in the art that fume, geothermal silica, fire retardant, Viscosity modifiers, the connections may take many different forms. In FIG.4, the thickeners, pigments, colorants, dispersants, foaming agents, connections take the form of tongue 45 and groove 47 forma flocculating agents, water-proofing agents, organic density tions defined on opposite longitudinal edges of the sheets. modifiers, aluminum powder, kaolin, alumina trihydrate, 55 Turning to FIG. 5, connections permit the sheet 400 to be mica, metakaolin, calcium carbonate, wollastonite, poly interlockingly engaged with an adjacent complementary meric resin emulsions, hydrophobic agents, or mixtures sheet, generally designated by the numeral 500. The adjacent thereof. Generally, these other additives may comprise complementary sheet 500 is characterized as having a top between about 0-40 wt % of the total formulation. face51, a bottom face 53, and connections, which as shown in The formulation may be formed into a green shaped article 60 FIG. 5, take the form of tongue 55 and groove (not shown) from a waterborne mixture or slurry by any number of suit formations defined on opposite longitudinal edges of the able processes, such as the Hatschek sheet process, Magnani complementary sheet. Tongue 55 generally extends from the process, injection molding, extrusion, hand lay-up, molding, main body of the sheet 500 and has a length 'x'', which is casting, filter pressing, flow on machine roll forming, etc., preferably in the range of 0.01 to about 3 inches. Comple with or without post pressing. In certain embodiments, 65 mentary sheet 500 may be interlockingly engaged with the Hatschek sheet process is the preferred method, such process corresponding groove 47 of adjacent sheet 400, having a being described in Australian Patent No. 515151. length “y”, preferably in the range of 0.01 to about 3 inches. US 8,209,927 B2 7 8 Sheet 400 and complementary sheet 500 may be interlock complementary building sheet is inserted into the groove ingly engaged to form a coplanar Support Surface, as shown in containing membrane during installation. FIG. 6. Examples of suitable membrane materials include, but are Referring still to FIG. 5, when a tongue and groove of not limited to, polyethylene, polypropylene, polyester, poly adjoining sheets are interlocked, using the sheets 400 and 500 5 acrylate, nylon, polyvinylalcohol, biaxially oriented polypro as examples, it is preferable that the length 'x' of tongue 55 pylene, polyethylene terephthalate, polyurethane, polya of the complementary sheet 500 be slightly shorter than the mide, polyacrylic, fluoropolymer films, acrylic, or any other length “y” of complementary grove 47 of sheet 400, such that Suitable material. In certain embodiments, the membrane is a cavity 61 (see FIG. 6) is created to allow for glue or adhesive constructed of polyethylene. Membranes useful in the present to be inserted. One of skill in the art will also appreciate that 10 invention may be prepared in various forms including flat the height of tongue 55 may be slightly smaller than the height sheets, tubes, capillaries and hollow fibers. Membranes use of grove 47, so as to provide further cavities in which glue/ ful in the present invention may be built in membrane systems adhesive may be inserted. The glue/adhesive acts to bond the like plate and frame, spiral-wound module, hollow fiber mod connection and/or seal the connection to moisture as required ule, and tube-in-shell module. The membrane may be placed for waterproofing wet areas Such as bathroom floors. 15 in the groove of the engineered fiber cement sheet during the The adjacent complementary sheet 500 may be formed forming of the membrane. Further the membrane may be from any material having complementary connections. Such formed during manufacture of the fiber cement sheet or as a further fiber cement sheet, a sheet of particle board, OSB installed after the fiber cement sheet has been formed. or any other suitable sheet. The membrane 79 may be substantially filled with an adhe While the embodiments shown in the accompanying fig sive. Suitable adhesive include, but are not limited to, poly ures illustrate connections having square or rectangular acrylate, polyvinyl ether, polyvinyl acetate, rubber (e.g., geometries, it will be appreciated that the cooperating natural rubber), polyisoprene, polychloroprene, butyl rubber, tongues and grooves may take any desired shape, and are not neoprene rubber, ethylene propylene diene rubber (EPDM), limited to the exemplary geometries given. Examples of Suit polyisobutylene, butadiene-acrylonitrile polymer, thermo able connections useful in fiber cement sheets of the present 25 plastic elastomers, styrene-butadiene rubber, poly-alpha-ole invention include, but are not limited to, biscuit join, bridle, fins, amorphous polyolefins, silicones, ethylene-containing butt, butterfly, dowel, coping, cope and Stick, dado, dovetail, copolymers (e.g., ethylene-acrylic acid, ethylene vinyl finger, lap, miter, mortise and tenon, pocket-hole, rabbet, acetate, ethylene ethyl acrylate, ethylene n-butyl acrylate, and Scarf, splice joint, tongue and groove, frame and panel, or any ethylene methyl acrylate), polyurethanes, polyamides, other Suitable connectors. In certain embodiments, tongue 30 epoxys, polyvinylpyrrolidone and polyvinylpyrrolidone and groove is the preferred connections. The connections copolymers, polyesters, and mixtures or copolymers thereof. may be formed on the board by any suitable process, such as The membrane substantially filled with adhesive may be by extrusion during the sheet formation process, or by formed by Suitable methods, such as, for example, extrusion, machining once Sufficient curing has taken place. Other Suit pultrusion, injection, blowing, and casting. The membrane able methods of forming the connections will be readily 35 may be formed as one piece or as multiple pieces. apparent to those skilled in the art. In one embodiment, a fiber reinforced cement sheet is EXAMPLES connected to an adjacent sheet of the same material. In another embodiment, a fiber reinforced cement sheet may be connected to an adjacent sheet comprising any Suitable con The following examples are presented to further illustrate struction material. Such as oriented Strand board, plywood, 40 embodiments of the present invention and are not to be con etc. Standard plywood and OSB for flooring typically have a Strued as unduly limiting the scope. tongue and groove joint. The fiber cement sheet may be Structural floors are required to meet certain standards. In configured with a tongue and groove joint to align and lock the US, fiber cement structural floors must be in compliance with the tongue and groove joint of wood flooring. This is with the Acceptance Criteria For Fiber Cement Sheet Struc particularly useful when the fiber cement flooring sheet is 45 tural Floor Sheathing AC367 as set by the International Code used only in wet areas, such as bathrooms, and wood flooring Council Evaluation Services (ICC-ES). The acceptance cri is used in an adjacent room, such as a bedroom. teria sets the minimum values for various properties, includ Turning to FIG. 7, there is illustrated an engineered fiber ing structural loads, deflection under load, flexural strength, sheet according to one embodiment of the present invention moisture movement, moisture content, water tightness, warm generally designated by the numeral 700. The fiber cement 50 water resistance, shear bond strength, nail-head pull through, sheet 700 is characterized by a fiber cement sheet having atop and fastener holding. As described further below, tests were face 71, a bottom face 73, and connections 75, 77 which take conducted to ascertain the strength of exemplary fiber cement the form of tongue 75 and groove 77 on opposite longitudinal sheets, as compared to other formulations. The structural edges. In FIG. 7, a membrane 79 filled with adhesive is shown loads are concentrated Static loads, impact loads, and uniform situated in the groove 77. The membrane 79 is configured 55 loads. The flooring must meet the minimum requirements of such that it breaks and releases adhesive when the tongue 75 all three load tests and deflections to be considered structural of one sheet is inserted in the groove 77 of a complementary flooring. sheet. Once the membrane 79 is broken, adhesive flows out of the membrane and into the cavity of the joint. The adhesive then substantially fills the cavity and adheres the sheets Example I together. 60 Membrane 79 is configured to encapsulate an adhesive and TABLES 1 and 2 below illustrate example fiber reinforced to resist puncture and/or breakage during transport and prior cement formulations of the present invention (Table 1) and to installation. Membrane 79 is also configured to permit test results for these formulations (Table 2), more particularly, puncture and breakage upon Sufficient contact with an edge of demonstrating the strength of the product as it relates to the an adjacent building material upon installation. Preferably, 65 products ability to withstand concentrated or static loads. membrane 79 is configured in such a way such that the mem About 500 sheets of flooring were manufactured to the prod brane is punctured after a majority of the tongue portion of a uct requirement specification and tested for strength criteria. US 8,209,927 B2 9 10 TABLE 1. TABLE 2 shows the requirements of concentrated static load based on the criteria for fiber reinforced cement single FORMULATIONS FORTABLE 2 RESULTS floor grade sheets. The fiber cement sheets with formulation 1 were tested in accordance with ASTM E661, and were tested LowAdditive Density 5 dry, and wet/redry (exposed to three days of continuous wet ting, followed by performing the test with re-dry samples). Portland Silica Cellulose Micro- Two criteria were tested: (1) ability to withstand a minimum Formula Cement Aggregate Fiber Additive spheres Calsil static peak load of 550 lbs under either dry or wet/redry 1 36 39.75 11.25 3 10 O condition at 16 inch, 20 inch, or 24 inch spans on centers, and (2) maximum deflection under 200 lbs of load (0.108 inch at 24 inch spans on center). TABLE 2

CONCENTRATED STATICLOAD TEST PERFORMANCE FOR PRODUCT FORMULATION 1 AS COMPARED TO CONCENTRATED STATICLOAD TEST PERFORMANCE CRITERIA FOR SINGLE FLOOR GRADE SHEETS

PERFORMANCE TEST PERFORMANCE REQUIREMENT RESULT REQUIREMENT TEST RESULT Static Static Maximum Maximum Span (Minimum (Minimum Deflection Deflection (in) Rating Conditions Peak Load, Peak Load, (in) under under 200-pound (in) attest lbs) lbs) 200-pound Load Load 24 Dry 550 880-100S O.108 O.O3S-O.O70 Wet/redry 550 900-1100 O.108 O.O45-0.06S

Example II so TABLE3 below illustrates fiber reinforced cement formu lations and test results for these formulations, more particu larly, demonstrating the effects of increased amounts of low density additives TABLE 3

FORMULATIONS HAVING INCREASEDAMOUNTS OF LOW DENSITY ADDITIVES AND EFFECTS ON CONCENTRATED STATICLOAD TEST PERFORMANCE

Portland Silica Cellulose LDA Static Form. Cement Aggregate Fiber Additive Microspheres Calsil Load Deflection 1 36 39.75 11.25 3 10 O 880 O.O3S 4 43.2 28.8 11.0 2 10 5 685 O.19 5 37.2 24.8 11.0 2 25 O S60 O.30

In TABLE 3, formulation 1 with 10% LDA exceeded the minimum requirements for strength and deflection to comply with AC 367. Formulations 4 and 5, with increased amounts of LDA, (15% and 25%, respectively) would lower the den sities of the fiber cement sheet to improve nailability. How ever, the products having formulations 4 and 5 did not meet the minimum standards for deflections under load after con ss centrated Static load testing, as the deflections for formula tions 4 and 5 (0.19 and 0.30) were above the minimum stan dard of 0.108 inch under 200 lbs of load.

60 Example III

TABLE 4 below illustrates fiber reinforced cement formu 65 lations and test results for these formulations, more particu larly, demonstrating the effects of decreased amounts of low density modifiers. US 8,209,927 B2 11 12 TABLE 4

FORMULATIONS HAVING DECREASEDAMOUNTS OF LOW DENSITY ADDITIVES AND EFFECTS ON CONCENTRATED STATICLOAD TEST PERFORMANCE

Portland Silica Cellulose LDA Static Form. Cement Aggregate Fiber Additive Microspheres Calsil Load Deflection 1 36 39.75 11.25 3 10 O 880 O.O3S 3 46.8 31.2 11.O 2 O 9 800 O.21

In TABLE 4, formulation 1 with 10% LDA exceeded the in accordance with the method described in EXAMPLE 1) minimum requirements for strength and deflection to comply were tested in accordance with ASTM E661, Procedure A, with AC 367. Formulation 3, with a decreased amount of using a 75 ft-lbf impact for span rating up to 24 inches on LDA (9%) resulted in a product that would not be strong center, and were tested dry, and wet/redry (exposed to three enough to meet minimum testing requirements, given that the days of continuous wetting, followed by performing the test deflections under load were well above the minimum stan with re-dry samples). 3 criteria were tested: (1) ability to dard of 0.108 in under 200 lbs of load. withstand a 75 ft/lbs impact (2) ability to withstand a mini mum proof load of 400 lbs following the impact under either Example IV dry or wet/redry conditions at 24 inch spans on centers or less, and (2) maximum deflection under 200 lbs of load after TABLE 5 shows the requirements of impact load based on impact (0.108 inch at 24 inch spans on center). The fiber the criteria for fiber reinforced cement single floor grade cement sheet of formulation 1 were able to withstand at least sheets. The fiber cement sheets with formulation 1 (prepared 120 ft/lbs impact. TABLE 5

IMPACT LOAD TEST PERFORMANCE FOR PRODUCT FORMULATION 1 AS COMPARED TOIMPACT LOAD TEST PERFORMANCE CRITERIA FOR SINGLE FLOOR GRADE SHEETS

PERFORMANCE REQUIREMENT TEST RESULT Maximum Maximum PERFORMANCE Deflection Deflection Span REQUIREMENT TEST RESULT (in) under (in) under Rating Conditions Impact (Minimum Impact' (Minimum 200-pound 200-pound (in) at test Peak Load, lbs) Peak Load, lbs) Load Load 24 Dry 400 400 O.108 O.O3O-O.O70 Wet/redry 400 400 O.108 O.O.30-0.06S The standard test requires withstanding a 75ft-lbfimpact. The test samples were able to withstand at least a 120ft-lbfimpact.

Example V 45 TABLE 6 illustrates test results of fiber reinforced cement formulations and test results for these formulations, more particularly, demonstrating the effects of decreased amounts of fibers and increased amounts of low density additives. TABLE 6

FORMULATIONS HAVING DECREASEDAMOUNTS OF FIBERS AND INCREASEDAMOUNTS OF LOW DENSITY ADDITIVES AND EFFECTS ON IMPACT LOAD TEST PERFORMANCE

Portland Silica Cellulose LDA Impact

Form. Cement Aggregate Fiber Additive Microspheres Calsil Load Deflection

1 36 39.75 11.25 3 10 O 400 O.O3O 2 38.9 25.35 9.75 3 23 O 400 O.118 US 8,209,927 B2 13 14 In TABLE 6, formulation 1 with 10% LDA and 11.25% What is claimed is: fibers exceeded the minimum requirements for impact and 1. A fiber cement sheet comprising: deflection to comply with AC 367. Formulation 2, with an cementitious matrix, reinforcing cellulose fibers distributed throughout the increased amount of LDA (23%) and decreased amount of matrix, said reinforcing cellulose fibers comprise about fibers (9.75%) resulted in a product that would not be strong 5 10% to 12% by weight, enough to meet minimum testing requirements, given that the a low density additive, said low density additive compris deflections under load were well above the minimum stan ing about 7% to 12% by weight, dard of 0.108 in under 200 lbs of load. wherein the fiber cement sheet has a dry density less than 1.25 g/cm, a thickness less than 0.7500 inches, Example VI 10 and able to withstand uniform loads of 200 psfor greater and TABLE 7 illustrates test results of fiber reinforced cement with an average deflection of less than 0.067 inches at 60 formulations of the present invention, more particularly, dem psf. onstrating the strength of the product as it relates to the able to withstand impact loads of 75 ft/lbs and a proof load products ability to withstand uniform loads. 15 of 400 pounds or greater following impact with a deflec TABLE 7 shows the requirements of uniform load based on tion of less than 0.108 inches under a 200 pound load the criteria for fiber reinforced cement single floor grade after impact, sheets. The fiber cement sheets with formulation 1 (prepared and in accordance with the method described in EXAMPLE 1) able to withstand concentrated static loads of 550 pounds were tested inaccordance with Sections 6.4.2.2 and 6.4.2.3 of or greater with a deflection of less than 0.108 inches PS2 published by the U.S. Department of Commerce and under a 200 pound load tested in accordance with a modified test method of Section when spaced on a span of 24 inches or less on center. 6.4.2.4 of PS2. The test was modified such that the specimens 2. The fiber cement sheet of claim 1, wherein the low were loaded at a uniform rate of 50 lb/ft per minute and density additive is selected from the group consisting of deflections measured at loading intervals of 20 lb/ft. The microspheres, callsil, treated callsil, polymeric beads, polysty specimens were tested dry, and wet/redry (exposed to three 25 rene beads, expanded vermiculite, expanded perlite, days of continuous wetting, followed by performing the test expanded shale, expanded clay, and the like and combinations with re-dry samples). 2 criteria were tested: (1) ability to thereof. withstand a minimum peak uniform load of 200 psfunder 3. The fiber cement sheet of claim 2, wherein the reinforc either dry or wet/redry conditions at 24 inch spans on centers, ing cellulose fibers are present in an amount of about 11% by and (2) maximum average deflection (0.067 at 60 psf). weight. TABLE 7

UNIFORMLOAD TEST PERFORMANCE FOR PRODUCT FORMULATION 1 AS COMPARED TO UNIFORMLOAD TEST PERFORMANCE CRITERIA FOR SINGLE FLOOR GRADE AND SHEATHING GRADE SHEETS

PERFORMANCE PERFORMANCE REQUIREMENT TEST RESULT REQUIREMENT TEST RESULT Span Uniform Uniform Average Average Rating Conditions Load (Peak Load, Load (Peak deflection deflection (in) attest psf) Load, pSf) under Load under Load 24 Dry 2OO 320-390 0.067 at 60 psf Wet/redry

45 As the above examples demonstrate, formulation 1 met and 4. The fiber cement sheet of claim 1, wherein the cemen exceeded the requirements of structural flooring for strength titious matrix comprises a hydraulic binder in an amount in and deflection. At spans of 24 inches on center, the specimens the range of from about 25 to about 40 weight percent. surpassed the minimum thresholds by at least 30%. It is the appropriate ratio of raw materials that impart the 50 5. The fiber cement sheet of claim 4, wherein the hydraulic necessary strengths to meet the structural load and deflection binder is Portland cement. requirements while maintaining the appropriate density and thickness. The ratio of the raw materials of cement, silica, 6. The fiber cement sheet of claim 1, further comprising an fibers, low density modifiers, and additives all have an effect aggregate distributed throughout the matrix, wherein the on the finished fiber cement sheet. It is a very narrow range of 55 aggregate is selected from the group consisting of ground the raw materials that supply the engineered fiber cement with silica, amorphous silica, silica fume, diatomaceous earth, rice the necessary strength and handleability to be considered hull ash, blast furnace slag, granulated slag, Steel slag, min structural flooring. eral oxides, mineral hydroxides, clays, magnasite, dolomite, Although the foregoing description of the preferred metal oxides, metal hydroxides, polymeric beads, and the like embodiments has shown, described and pointed out certain and mixtures thereof. novel features of the invention, it will be understood that 60 various omissions, Substitutions, and changes in the form of 7. The fiber cement sheet of claim 6, wherein the aggregate the detail as illustrated as well as the uses thereof, may be made by those skilled in the art, without departing from the is present in an amount in the range of from about 30 to about scope of the invention. Particularly, it will be appreciated that 45% by weight. the preferred embodiments may manifest itself in other 65 shapes and configurations as appropriate for the end use of the article made thereby.